11_Manufacturing_1-9

D / 6.

Dimensional accuracy, smoother surface finish, ability to cast very thin sections, and requires a small amount of sand.

A narrow jet of water is directed at high pressure and velocity.

The relationship between cutting speeds and angles.

Different types of views of cutting tools.

Constant current welding machines.

Ra = (4 * tan(cot(s) * e * h * f * C) + C) / 4.

A process where ceramics are formed around wax patterns to create a casing for molten metal.

A downward feed force, F.

It produces coalescence over the entire area of abutting surfaces by heat obtained from resistance to electric current.

The magnitude of strain that develops along the shear plane due to machining action.

0.5 to 10 V.

Rod diameter.

At the interface between the two plates being joined.

It illustrates the force relations in orthogonal cutting.

Electro Chemical Machining.

A process where sand mixed with thermosetting resin is allowed to contact a heated metal pattern to form a shell.

Gating ratio is defined as the ratio of sprue area to runner area to ingate area.

Expensive patterns, small size castings only, cannot obtain highly complicated shapes, and requires sophisticated equipment.

The sprue is tapered to gradually reduce the cross section and eliminate the problem of air aspiration.

D / 6.

It refers to the shape and angles of the cutting tool used in turning operations.

A process in which molten metal flows by gravity or other force into a mold where it solidifies in the shape of the mold cavity.

It utilizes heat from a high-power concentrated laser beam to melt metal interfaces.

Flow rate of abrasives.

A specific type of casting process that uses sand as the mold material.

r = ct / c0 = sin(φ) / cos(φ - α).

A single point cutting tool.

A non-traditional machining method that uses a narrow jet of water directed at high pressure and velocity against the surface of a workpiece.

1/10th or 10% of the shear plane length.

Material Removal Rate.

Mean diameter of abrasives.

The cutting edge is wider than the workpiece width and extends beyond the workpiece on either side.

Straight sprue and tapered sprue.

D / 6.

A welding technique similar to flash welding that uses a rapid discharge of stored electrical energy to create an intense arc for a very short duration.

Risers must solidify after the casting.

Spark energy, calculated as E s = (1/2) × C × V c^2 / cycle.

It can carburize metal.

A welding process where an arc is generated between cathode and anode to establish the flow of current.

v = π * D * N, where N is the spindle speed.

It relates the weight of a material to current and time.

For intricate castings where withdrawal from the mould is difficult.

Sliding of the tool along the machined surface and temperature rise.

When DC is used and the work is positive (the anode of the circuit).

Electro Chemical Machining (ECM).

Abrasive Jet Machining.

19 to 25 kHz.

15 to 50 μm.

A welding process that uses heat generated by electric current to join metal pieces, capable of welding thicker materials than spot welding.

τ = R c × C.

Up to 100,000 A.

Flash welding uses arc heating instead of resistance heating.

A process by which two materials, usually metals, are permanently joined together by coalescence induced by temperature, pressure, and metallurgical conditions.

Cooling rate.

Core sand should be of higher strength than moulding sand.

Gas welding.

x must be greater than 1.

Shear force.

V (cutting speed), T (time), n (exponent), C (constant).

To prevent contamination of the electrode.

Oxy-fuel welding (fusion welding).

Vc = Vchip / Vtool.

Mechanical properties of centrifugally cast jobs are better compared to other processes.

A solid-state welding process that generates heat through mechanical friction between workpieces in relative motion.

About 3.5 mm.

h = tan(cot(s) * e * f * C) + C.

2(ab / (a + b)).

It helps in understanding the cutting process and tool engagement.

The die casting alloy is melted in a furnace located within the equipment.

Short circuit current.

A slurry of plaster, water, and various additives.

The cutting forces act along two directions only.

A process using artificially composed loam made of brick-clay and sharp sand, restricted to forms that cannot be cast conveniently in other processes.

A shape factor.

Resistance seam welding uses wheel-shaped electrodes and the workpiece rolls between them.

To integrate the gating and runner system with the pattern, improving productivity by eliminating hand cutting.

Total solidification time (t_s) = n * (V_B / A), where n = 1.5 to 2.0.

65% to 75% heat is generated at the anode.

P_c = F_c / A, where F_c is the cutting force and A is the cross-section area of the undeformed chip.

Constants used in the equation for calculating x.

Two halves of the pattern along with gating and riser systems, attached to plates with alignment pins.

A low-voltage high-current electrical process.

60%.

Modulus = Volume / Surface area.

ε̇ = V_s / t_s, where t_s is the thickness of the shear zone.

MRR is proportional to QD, where Q is the flow rate of abrasives and D is the mean diameter of abrasives.

Ranging between 4 and 10.

h = 2 * 8 * f * R.

Different parameters such as pressure, velocity, and nozzle design.

MRR = (3 eq EI cm^3)/(F sec) where eq = (100 F ρ)/(Σ i xi 100 x v and E A)

Tool changing time (in minutes).

The wear rate is constant.

High welding speeds and high deposition rates.

Wear gradually increases.

An inexpensive and the simplest type of pattern.

A good riser shape has a long freezing time, meaning a small surface area per unit volume.

It generates heat by an electric current passing between a consumable electrode and the workpiece through molten slag.

About 3000°C.

Vs = Vchip / Vmaterial.

Molten metal is introduced into a rotating mold and held against the mold wall by centrifugal force until solidified.

96,500 coulombs.

Labour cost and overhead cost per minute.

To account for depth of cut and feed rate in tool life calculations.

A pattern where cope and drag patterns, along with gating and riser ring, are mounted on a single matching plate.

To drive away other atmospheric gases from the weld zone.

R = F_c * t * F * sin(α) + F * cos(α).

Low numbers mean a few massive grains; high numbers refer to many small grains.

φ = (4/2) * π * (α + β) - (b).

1. Low heat penetration 2. Excessive weld spatter.

It is done at room temperature and can occur in air, water, or vacuum.

Filling time in the top gate.

A process where a beam of electrons is magnetically focused on the work piece in a vacuum chamber.

The sprue is the channel through which molten metal is brought into the parting plane to enter the runners and gates, ultimately reaching the mould cavity.

It is the reverse of electroplating.

MRR = (3 AI cm^3)/(vF sec) = (3 EI cm^3)/(F sec)

The maximum rated voltage between open terminals under no loading conditions.

A process where molten metal is poured into an open face die, and a punch applies pressure while the part solidifies.

It represents the current (I) in terms of applied voltage (V), over voltage (∆V), and resistance (R).

ϵ = cot(φ) * tan(φ - α).

Carburizing flame.

To obtain power estimates.

A_c is the cross-section area of the uncut chip (mm²).

Electrochemical Machining (ECM).

Oxygen and acetylene.

It preheats the air blast using flue gases, resulting in higher temperatures than conventional cupolas.

To accelerate the cooling of various regions and promote directional solidification.

T_sp : T_cy : T_cu = 1 : 0.763 : 0.649.

By proper feeding of liquid metal and placing risers in the mold.

Shrinkage, draft, machining, distortion, and rapping allowances.

Pieces of metal placed within the mold cavity to absorb heat and promote rapid solidification.

The reduction in volume when metal changes from liquid to solid state.

1. Large heat loss into atmosphere 2. Unstable arc 3. Weld pool is not protected 4. Weld has low strength, less ductility, poor fusion, and excessive spatter.

No, turning is not orthogonal cutting (2-D).

For castings with structurally weak portions that need support during ramming.

A replica of the final object to be made, with some modifications.

A consumable electrode.

To burn the metal and blow it away, causing the cut (kerf).

sin(2v) = sin(2s) * (v/cos(φ - α))

25 microns.

Constant voltage machines.

Wear ratio = Volume of metal removed from work / Volume of metal removed from tool.

The work-piece is made the anode.

Ra = 2 * 18 * 3 * f * R.

i c = (1 / R) × V 0 × e^(-t/τ).

H = I² × R, where I is the current and R is the resistance of the electrolyte in the gap.

Tooling cost (in Rs. per servicing or replacement).

The freezing ratio, which is the ratio of cooling characteristics of casting to the riser.

Drooping characteristics to maintain constant current when arc length changes.

To increase the cooling rate of castings.

Open circuit voltage (V 0), charging resistance (R), and capacitance (C).

v stands for valency.

Laser beam welding < MIG welding < Submerged arc welding < Arc welding.

Acetylene (C2H2).

5.08 cm.

The number of minutes within a 10-minute period a welder can safely produce a particular welding current.

No, pressure is not involved.

1. Heat is concentrated 2. More stable 3. More protective atmosphere.

Turning is 3-D cutting.

The ability of gases to escape through the core.

The reduction in volume when a metal loses temperature in the solid state.

When welding some nonferrous alloys such as copper-base alloys and zinc base alloys.

It is a non-traditional machining method.

Gravity or other forces.

It solidifies in the shape of the mold cavity.

Open circuit voltage.

It indicates that the height of the top gate equals the height of the bottom gate.

To facilitate the machining process.

The chip generated flows on the rake face of the tool with chip velocity perpendicular to the cutting edge.

The atomic weight of the work material.

Low melting point alloys.

H_e = q ρ_e c_e (T_f - T_i), where q is the flow rate, ρ_e is the density, c_e is the specific heat, T_i is the initial temperature, and T_f is the final temperature.

Machining cost (in Rs. per minute).

It relates cutting speed, time, and tool life.

SF = Length + Width + Thickness.

A reservoir of molten metal that allows hot metal to flow back into the mould cavity during solidification.

Linseed oil, core oil, resins, dextrin, molasses.

To cut metals that are difficult to cut by oxy-fuel cutting, such as cast iron and stainless steel.

Mostly cast iron, although wood is also used sometimes.

About 3300° C in the oxidizing flame.

It is preferred by smaller foundries for melting metal.

Flank wear occurs at low speed and is referred to as 'slow death.'

20.268 cm².

A flame produced with a higher oxygen/acetylene ratio (O2 > C2H2), hotter than the neutral flame.

Strainer, Bottom well, and Skim bob.

Defects caused by the trapping of gas in molten metal or mold gases during pouring.

Molten metal entering gaps between sand grains, resulting in a rough surface.

The dividing line between the two moulding flasks that makes up the sand mould.

Fc (horizontal) and Ft (vertical).

Freshly prepared refractory material used for making the mould cavity, typically a mix of 90% sand, 3% water, and 7% clay.

r = sin(φ) / (cos(φ) * V t / V l).

Negative: 70% heat at work end; Positive: 30% heat at work end.

Very low between the overlapping plates.

Exceptional surface polish, high dimensional precision, ability to cast complicated elements, and compatibility with almost any metal.

A high-amperage direct current through an electrolyte.

To feed liquid metal to the solidifying casting and compensate for solidification shrinkage.

The maximum rated current required during arc generation.

J = I / A, where A is the cross-sectional area of the electrode.

A welding process that uses heat from an exothermic reaction between metal oxides and reducing agents to produce coalescence between metals.

Less than 0.3% carbon.

Vc = Vmaterial + Vtool.

Aluminum, Copper, Brass, Magnesium, etc.

The ratio of the volume of the riser to the volume of the casting.

Tool regrind cost and tool depreciation per service/replacement.

It is changed to a metal oxide, which is then ground away by the abrasives.

1. Deoxidizing agent 2. Arc stabilizing agent 3. Slag forming agent.

t0 = fsin(λ), where f is feed and λ is approach angle.

When the work is negative and the electrode is positive.

A process that uses an ionized gas jet to cut materials resistant to oxy-fuel cutting.

The upper moulding flask.

1:1.

A phenomenon that occurs during the welding of magnetic materials with DC, particularly noticeable with bare electrodes.

w = d/sin(λ), where w is width of chip and d is depth of cut.

Between 800°C to 1000°C.

It represents the friction angle.

In DC welding with bare electrodes.

Made up of used and burnt sand.

The passage through which molten metal from the pouring basin reaches the mould cavity.

Yes, it occurs once every half cycle.

T_o = 1/T_c * (C_n / (C_m + C_t))

Primary wear zone, Secondary wear zone, Tertiary wear zone.

Hot Chamber Die Casting has a higher production capacity due to shorter casting cycles.

V c = 0.72 × V 0.

To support cores inside the mould cavity.

Temperature, pressure, and metallurgical conditions.

It has longer casting cycles, resulting in less product capacity.

It accounts for all the heat losses in the system.

T_o = 1/T_c * (n / (n - 1))

A rotating, metal bonded, diamond grit grinding wheel.

Heat input = b Vl A v (Joule/mm³)

A replica of the object to be made, with modifications.

Core oil (1%) and water (2.5 to 6%).

Flank wear, crater wear, and chipping off of the cutting edge.

The lower moulding flask.

A flame produced with an oxygen/acetylene ratio of about 1:1, which is chemically neutral.

They act as an insulating spacer.

Used when the contour of the part makes it difficult to withdraw the pattern from the mould.

Argon, helium, nitrogen, carbon dioxide, and mixtures of these gases.

Provide a protective atmosphere, stabilize the arc, provide protective slag, reduce spatter, add alloying elements, and affect arc penetration.

10 to 200 kHz.

Continuous chip, Discontinuous chip, Continuous chip with Built-Up Edge (BUE).

A type of resistance welding that joins metals by applying pressure and passing current.

h t = h s + h c.

Pressure vessels, ship bridges, LPG cylinders, etc.

The passageways in the parting plane through which molten metal flow is regulated before reaching the mould cavity.

Costly patterns and molds, high labor costs, and limited size.

To make cavities and hollow projections.

MRR = A_c * v = w * t_0 * v.

Low voltage and high current.

OCV + SCC = V.

It is the most widely used furnace for melting cast iron.

Reverse polarity.

Circular disc.

Liquid shrinkage occurring during the solidification of the casting.

It affects the current flow and efficiency of the machining process.

Flux coating, Flux granules, CO2, Vacuum.

F_c.

10 g/cm².

Semi-Centrifugal Casting uses centrifugal force to assist the flow of metal from a central reservoir to the extremities of a rotating mold.

The heat source is isolated from the charge, allowing slag and flux to get heat directly from the charge.

100%.

Occurs when a portion of the mold face lifts or breaks down, filled by metal.

Around 3200°C.

The normal force in the Merchant Circle Diagram.

2000 cm³.

Millions of psi.

10-50 mm.

A small funnel-shaped cavity at the top of the mould into which molten metal is poured.

It results in a lower deposition rate.

A represents the atomic weight.

Clay-free silica sand.

Its melting temperature is lower than iron oxide.

A box-like structure made of rectangular or circular walls, without a bottom or top.

Normal to shear force.

Electric Arc Furnace.

High-heat-capacity, high-thermal-conductivity materials.

If the modulus of the riser exceeds the modulus of the casting by a factor of 1.2, feeding during solidification is satisfactory.

Net Buoyancy Force = Weight of Liquid Metal Displaced – Weight of Core.

As a powder, in a flux paste, or pre-coated on rods.

Insufficient strength of molding sand and high velocity of molten metal flow.

200 mm.

To allow gases evolving from molten metal to escape.

An arc is established between a non-consumable tungsten electrode and the workpiece.

No other materials are needed to create the bond, making it cost-effective.

A pattern made of strips of wood used to build the final pattern by packing sand around it.

Inclination angle (i), orthogonal rake angle (α), side relief angle (γ), end relief angle (γ1), end cutting edge angle (C e), principal cutting edge angle (λ), and nose radius (R).

Critical velocity and critical angle.

Occurs when cope and drag or molding boxes are not properly aligned.

The cutting edge is perpendicular to the direction of cutting velocity.

By injecting finely divided 200-mesh iron powder into the flame.

Rough spots and areas of excess metal caused by erosion of molding sand by flowing metal.

Thrust component.

Cutting speed.

Crater wear occurs at high speed and is also referred to as 'slow death.'

An intermediate moulding flask used in three-piece moulding.

The joining of metals by applying pressure and passing current through the metal area to be joined.

To generate large shapes that are axi-symmetrical or prismatic, such as bell-shaped or cylindrical.

Fusion of sand grains with molten metal, giving a brittle, glassy appearance.

A board, normally made of wood, used at the start of the mould making.

Particles of slag, refractory materials, or deoxidation products trapped in the casting.

5 m/min.

Globular, spray, and short-circuit.

Cutting speed (in m/min).

It is a lateral force that plastically displaces and fuses the materials.

A variation of the permanent mold process where metal remains in the mold until a shell of desired thickness forms, then the remaining liquid is poured out.

'd' represents depth of cut and 'f' represents feed rate.

It signifies 'sudden death' of the tool.

R = VH / pAT.

Because it minimizes the time taken to fill the mold and the temperature gradient.

Between a consumable electrode and the workpiece.

Metals prone to brittle joints when heat welded, such as aluminum on steel and titanium on steel.

Used for making hollow cavities in castings.

It is another name for the inverse of chip ratio (h), where h > 1.

The metal added during a single pass of welding, made of the same material as the base metal.

Because they become part of the final casting.

A solid-state welding process that uses high-frequency vibrations to join materials under light pressure.

Wood, metal, and wax (for investment casting).

Blowholes and pinhole porosity.

Rake (α b α s), relief (γ e γ s), cutting edge (C e C s), side comes last, finish with nose radius (inch).

Movement of the mold wall under met allostatic forces.

t bottom = 2(1)(2) t t g A h h H A g - -.

h = 1/r, where r < 1.

50% at work end and 50% at electrode end.

N = 2n - 1.

They are more dimensionally stable and durable.

Electromagnetic forces.

The arc is submerged under solid flux, preventing heat transfer loss and splashing.

When metal is unable to fill the mold cavity completely, leaving unfilled cavities.

Difficult tasks such as overhead welding.

Using a dynamometer.

For orthogonal cutting, i = 0; for oblique cutting, i ≠ 0.

tan(φ) = (cos(α) / sin(α)) * (1 - r) / r.

Deep and narrow.

λ = 90 - C s.

When two streams of metal do not fuse together properly in the mold cavity.

The actual entry point through which molten metal enters the mould cavity at a controlled rate.